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Seal Assembly / Cement Failure Technical Evaluation
API’s 2015 Exploration and Production Standards on Oilfield Equipment and Materials
Summer Meeting
Doug Morris Joseph Levine Candi Hudson
San Francisco, CA June 23, 2015
BSEE Mission Statement “To promote safety, protect the environment and conserve resources offshore through vigorous regulatory oversight and enforcement.”
2
Presentation Overview
BSEE Mission BSEE History BSEE Regulatory Model Liner Seal and Cementing Failure
Technical Evaluation
3
BSEE: History
June 2010
October 2010
October 2011
Minerals Management
Service (MMS)
Bureau of Ocean Energy Management, Regulation & Enforcement
(BOEMRE)
Office of Natural Resources Revenue
(ONRR)
Bureau of Ocean Energy Management
(BOEM)
Bureau of Safety and Environmental Enforcement
(BSEE)
4
BSEE: Who We Are
Staffing: 795 Employees 200 engineers 100 inspectors
Locations Headquartered in DC & Sterling, VA Three regional offices
Gulf of Mexico – New Orleans, LA Pacific – Camarillo, CA Alaska – Anchorage, AK
Regional District Offices
5
BSEE Regulatory Model
Hybrid regulatory system Program draws from a variety of
concepts Model contains 3 key elements
Prescriptive requirements Performance-based initiatives Industry Standards
6
BSEE Technical Evaluations
Conduct QA/QC evaluations on manufacturedequipment Evaluate “Fitness for Service” of manufactured
equipment Identify gaps in industry practices/standards
and/or regulations Enhance regulator and industry knowledge
through evaluation findings Focus on issues that have potential industry
wide (global) impacts Not the same as traditional BSEE OIR, 2010 or
panel report investigations
7
Technical Evaluations to Date
Four evaluations since 2/2013 H4 Connector Bolt Failure
Completed 8/2014 Report posted on BSEE website
Seal Assembly/Cement Failure Completed 12/2014 Report posted on BSEE website
Two evaluations in progress Wing-Valve Assembly HC Connector Bolt Failure
May have similar issues as the 8/2014 evaluation
8
Liner Seal/Cementing Failure Technical Evaluation
While drilling operator took a gas kick (2/2013) Kick resulted in a gas flow into a shallow sand
below the conductor casing shoe culminating in an underground blowout Event created risk of broaching to the seafloor Possible failure points
Casing hanger seal Cement column in conductor/surface liner annulus Hole in casing Damaged casing threads
9
Area of Concern WL
Mu~wa<! ~e>th
1000'
2000'
3000'
C.sing
3e• 0r,ve
22" CondudO<
1g• Surfaoe / Drilling L ine,
Open Hole
12/2014 BSEE SRS REPORT- LINER
SEAUCEMENTING
Top of Mud Line Hanger
ML
+- Conductor Cement
+----Surface/Drilling Liner Cement 24" Hole
Open Hole ----
10
Liner Seal/Cementing Failure Technical Evaluation
Major Issues Are the Shallow Liner
Seal/Cement Column a single or dual barrier system? Can cement practices
for shallow sections of a well be improved upon? What criteria need to
be evaluated to ensure Shallow Liner Seals are “Fit for Service”?
11
Shallow Liner Seal/Cement Column; Single or Dual Barrier?
, Liner Seal 1
Meuuted Applied surface Oeoth Casing pressure
36" Oriv• I ' • 1000' ,.. 'I ., • - ( Conductor Cement
22" Conducte<
2000' -:woo· . Surface Drilling Liner/ - 18" Surface / Drilling liner I -
Cement (Barrier)
Open Hole
12
Liner Seal/Cementing Failure Unanswered Questions Are the Shallow Liner Seal/Cement Column a single ordual barrier?
If the liner seal is faulty are you actually testing the cement column?
How would you know?
Does a successful liner pressure test mask a poor cement job?
How would you know?
Is the integrity of the cement column behind the liner truly understood?
How could you determine the cement integrity?
13
API RP 96
Deepwater Well Design and Construction
First Edition, March 2013
14
Liner Seal/Cementing Failure Unanswered Questions
What criteria need to be evaluated to ensure Shallow Liner Seals are “Fit for Service”?
Temperature Rating Seal Assembly was rated to 75oF but was exposed to 90oFduring operation Inconsistencies between operator and OEM concerning seal’stemperature rating
Gas vs Liquid Rating Seal design was not qualified for gas, yet gas was “seen” in the well
Are there other design criteria that need to be evaluated? Pressure Axial loads
15
API 17D Hanger Industry Standards
No current standards exclusively address all liner hangers orseals Shallow Liner Hanger hung off of a submudline casing hanger is considered part of the Wellhead API Spec 17D Design & Operation of Subsea Production Systems Subsea Wellhead & Tree Equipment
First Edition (2003) Hydrostatic pressure tests shall be acceptable for all performance verification pressure tests Liner hanger and seal were designed to First Edition
Second Edition (2011) Gas shall be used as the test medium for pressure-hold periods for ressure-containing and controlling equipment p
3 pressure/load and temperature cycling tests required Would incorporation of 17D second edition in BSEEregulations address our concern with shallow liner seal “Fit for Service” issues?
16
API RP 19LH Hanger Industry Standards
API RP 19LH Liner Hangers First Edition to be published in 2016
Will not cover shallow surface liners, only production linerhangers
Scope (as of May 2014) Provides requirements & guidelines for conventional and
expandable liner systems including liner hangers, linerpackers, tie back and polished bore receptacles, sealstems, landing collars & running/setting tool components Provides minimum requirements for the functional &
technical specification, including design, design verification and validation, materials, documentation and data control, repair shipment and storage.
Incorporation of 19LH in BSEE regulations willnot address our concerns with shallow liner seal “Fit for Service” issues 17
Liner Seal/Cementing Failure Unanswered QuestionsSurface Drilling Liner/Shallow Hole Section Cement Concerns
Is BSEE liner lap/liner pressure test sufficient to prove reliability of the barrier(s)?
Can not decline more than 10% in a 30-minute test What is the engineering basis for this metric?
Is annular fill to at least 200 feet above conductor shoe adequate? Is WOC of 12 hours with cement held under pressure adequate?
WOC times shall be adequate to achieve a minimum of 500 psicompressive strength at the casing shoe prior to drilling out How is this determined? (in a lab, estimation)
Is there an ideal open hole diameter/surface liner OD ratio? What annular space is too large/small?
Other suggestions?
18
API RP 65 First Edition, September 2002 Cementing Shallow Water Flow Zones in Deepwater Wells Incorporated in BSEE Regulations
Appendix B.2- Hole Size Define optimum hole size to achieve effective mud
removal and annular isolation Consider annular dimensions with casing in the hole to
allow for placement of cement at desired rates Control drilling mud properties to minimize large
washouts Appendix F; Table A-2 – Hole Diameter
Hole diameter should be a minimum of 3.0 inches greater than the casing outer diameter
Does this provide sufficient guidance in planningopen hole geometry?
19
API STD 65-Part 2 Second Edition, December 2010 Isolating Potential Flow Zones During Well Construction Incorporated in BSEE Regulations
Section 5.2: Hole Quality Where hole quality could compromise cementing quality
Avoid severe doglegs, hole enlargement, and spiral patterns to improve drilling fluid displacement during cementing Use of directional survey dat a when modeling centralization & drilling luid displacement to improve the simulation accuracy f
Annex D Hole Diameter - Is hole enlargement minimized sufficiently to allow for adequate centralization? Centralizer placement simulations shall be performed Have the centralizer simulator results been considered during the cementing design and execution?
Does this provide sufficient guidance in planning open hole geometry?
20
30 CFR 250.420 – What Well Casing and Cement Requirements Must I Meet?
BSEE Blowout Preventer Systems and WellControl Proposed Rule
Proposed Change: Add new paragraph (a)(6) - require adequate
centralization to help ensure proper cementation Will this requirement be of value in
improving cementing of shallow casing/linersections of a well? Can centralizers be run in shallow sections
of a well? 21
Opportunities for Improvement with Standards
Are existing standards adequate for sealdesign/qualification?
API 17D - Second Edition (2011) Should this be incorporated into BSEE regulations?
API 19LH - First Edition (Publish 2016) Should they be modified? How?
Are existing BSEE regulations and standardsadequate for cementing?
RP 65 - First Edition STD 65-2 - Second Edition 30 CFR 250 Should they be modified? How?
22
Possible Research
Shallow Liner/Cement JIP to Evaluate if Seal and Cement are a Single or Dual Barrier
1) Scaled laboratory testing of liner seals with associated annular cements to help determine if we are dealing with a single or dual barrier
Vary type of liner seal, open hole diameter/surface liner ODratio Test at various pressure and temperature combinations Test with different classes and densities of cement
Evaluate performance of seals and cements ability to hold applied pressure in regards to preventing leaks Develop performance curves for seals and cements at
pressure and temperature combinations
2) Investigate/evaluate different sealing system optionsfor use downhole in shallow sections of a wellbore
23
Are Additional Clarifying Regulations Needed?
24
BSEE Website: www.bsee.gov
@BSEEgov
BSEEgov
Bureau of Safety andEnvironmental Enforcement
“To promote safety, protect the environment and conserve resources offshore through vigorous regulatory
oversight and enforcement.”